Translatable articulation joint unlocking feature for surgical stapler

ABSTRACT

An apparatus comprises a body, a shaft assembly, an end effector, and an articulation joint. The end effector is operable to manipulate (e.g., staple) tissue. The articulation joint couples the end effector with the shaft assembly and permits the end effector to deflect away from the longitudinal axis of the shaft assembly. The articulation joint comprises a locking assembly, which is operable to selectively lock the angular position of the end effector relative to the longitudinal axis. The locking assembly comprises a first locking member and a second locking member. The first locking member is unitarily secured to the end effector. The second locking member is movable along a first axis to selectively engage the first locking member to thereby selectively lock the angular position of the end effector relative to the longitudinal axis of the shaft assembly. The first axis is perpendicular to the longitudinal axis.

BACKGROUND

In some settings, endoscopic surgical instruments may be preferred overtraditional open surgical devices since a smaller incision may reducethe post-operative recovery time and complications. Consequently, someendoscopic surgical instruments may be suitable for placement of adistal end effector at a desired surgical site through the cannula of atrocar. These distal end effectors may engage tissue in a number of waysto achieve a diagnostic or therapeutic effect (e.g., endocutter,grasper, cutter, stapler, clip applier, access device, drug/gene therapydelivery device, and energy delivery device using ultrasonic vibration,RF, laser, etc.). Endoscopic surgical instruments may include a shaftbetween the end effector and a handle portion, which is manipulated bythe clinician. Such a shaft may enable insertion to a desired depth androtation about the longitudinal axis of the shaft, thereby facilitatingpositioning of the end effector within the patient. Positioning of anend effector may be further facilitated through inclusion of one or morearticulation joints or features, enabling the end effector to beselectively articulated or otherwise deflected relative to thelongitudinal axis of the shaft.

Examples of endoscopic surgical instruments include surgical staplers.Some such staplers are operable to clamp down on layers of tissue, cutthrough the clamped layers of tissue, and drive staples through thelayers of tissue to substantially seal the severed layers of tissuetogether near the severed ends of the tissue layers. Merely exemplarysurgical staplers are disclosed in U.S. Pat. No. 4,805,823, entitled“Pocket Configuration for Internal Organ Staplers,” issued Feb. 21,1989; U.S. Pat. No. 5,415,334, entitled “Surgical Stapler and StapleCartridge,” issued May 16, 1995; U.S. Pat. No. 5,465,895, entitled“Surgical Stapler Instrument,” issued Nov. 14, 1995; U.S. Pat. No.5,597,107, entitled “Surgical Stapler Instrument,” issued Jan. 28, 1997;U.S. Pat. No. 5,632,432, entitled “Surgical Instrument,” issued May 27,1997; U.S. Pat. No. 5,673,840, entitled “Surgical Instrument,” issuedOct. 7, 1997; U.S. Pat. No. 5,704,534, entitled “Articulation Assemblyfor Surgical Instruments,” issued Jan. 6, 1998; U.S. Pat. No. 5,814,055,entitled “Surgical Clamping Mechanism,” issued Sep. 29, 1998; U.S. Pat.No. 6,978,921, entitled “Surgical Stapling Instrument Incorporating anE-Beam Firing Mechanism,” issued Dec. 27, 2005; U.S. Pat. No. 7,000,818,entitled “Surgical Stapling Instrument Having Separate Distinct Closingand Firing Systems,” issued Feb. 21, 2006; U.S. Pat. No. 7,143,923,entitled “Surgical Stapling Instrument Having a Firing Lockout for anUnclosed Anvil,” issued Dec. 5, 2006; U.S. Pat. No. 7,303,108, entitled“Surgical Stapling Instrument Incorporating a Multi-Stroke FiringMechanism with a Flexible Rack,” issued Dec. 4, 2007; U.S. Pat. No.7,367,485, entitled “Surgical Stapling Instrument Incorporating aMultistroke Firing Mechanism Having a Rotary Transmission,” issued May6, 2008; U.S. Pat. No. 7,380,695, entitled “Surgical Stapling InstrumentHaving a Single Lockout Mechanism for Prevention of Firing,” issued Jun.3, 2008; U.S. Pat. No. 7,380,696, entitled “Articulating SurgicalStapling Instrument Incorporating a Two-Piece E-Beam Firing Mechanism,”issued Jun. 3, 2008; U.S. Pat. No. 7,404,508, entitled “SurgicalStapling and Cutting Device,” issued Jul. 29, 2008; U.S. Pat. No.7,434,715, entitled “Surgical Stapling Instrument Having MultistrokeFiring with Opening Lockout,” issued Oct. 14, 2008; U.S. Pat. No.7,721,930, entitled “Disposable Cartridge with Adhesive for Use with aStapling Device,” issued May 25, 2010; U.S. Pat. No. 8,408,439, entitled“Surgical Stapling Instrument with An Articulatable End Effector,”issued Apr. 2, 2013; and U.S. Pat. No. 8,453,914, entitled “Motor-DrivenSurgical Cutting Instrument with Electric Actuator Directional ControlAssembly,” issued Jun. 4, 2013. The disclosure of each of theabove-cited U.S. Patents is incorporated by reference herein.

While the surgical staplers referred to above are described as beingused in endoscopic procedures, it should be understood that suchsurgical staplers may also be used in open procedures and/or othernon-endoscopic procedures. By way of example only, a surgical staplermay be inserted through a thoracotomy, and thereby between a patient'sribs, to reach one or more organs in a thoracic surgical procedure thatdoes not use a trocar as a conduit for the stapler. Such procedures mayinclude the use of the stapler to sever and close a vessel leading to alung. For instance, the vessels leading to an organ may be severed andclosed by a stapler before removal of the organ from the thoraciccavity. Of course, surgical staplers may be used in various othersettings and procedures.

Examples of surgical staplers that may be particularly suited or usethrough a thoracotomy are disclosed in U.S. Pub. No. 2014/0243801,entitled “Surgical Instrument End Effector Articulation Drive withPinion and Opposing Racks,” published Aug. 28, 2014, now U.S. Pat. No.9,186,142, issued Nov. 17, 2015; U.S. Pub. No. 2014/0239041, entitled“Lockout Feature for Movable Cutting Member of Surgical Instrument,”published Aug. 28, 2014, now U.S. Pat. No. 9,717,497, issued Aug. 1,2017; U.S. Pub. No. 2014/0239042, entitled “Integrated TissuePositioning and Jaw Alignment Features for Surgical Stapler,” publishedAug. 28, 2014, now U.S. Pat. No. 9,517,065, issued Dec. 13, 2016; U.S.Pub. No. 2014/0239036, entitled “Jaw Closure Feature for End Effector ofSurgical Instrument,” published Aug. 28, 2014, now U.S. Pat. No.9,839,421, issued Dec. 12, 2017; U.S. Pub. No. 2014/0239040, entitled“Surgical Instrument with Articulation Lock having a Detenting BinarySpring,” now U.S. Pat. No. 9,867,615, issued Jan. 16, 2018; U.S. Pub.No. 2014/0239043, entitled “Distal Tip Features for End Effector ofSurgical Instrument,” published Aug. 28, 2014, now U.S. Pat. No.9,622,746, issued Apr. 18, 2017; U.S. Pub. No. 2014/0239037, entitled“Staple Forming Features for Surgical Stapling Instrument,” publishedAug. 28, 2014; U.S. Pub. No. 2014/0239038, entitled “Surgical Instrumentwith Multi-Diameter Shaft,” published Aug. 28, 2014, now U.S. Pat. No.9,795,379, issued Oct. 24, 2017; and U.S. Pub. No. 2014/0239044,entitled “Installation Features for Surgical Instrument End EffectorCartridge,” published Aug. 28, 2014, now U.S. Pat. No. 9,808,248, issuedNov. 7, 2017. The disclosure of each of the above-cited U.S. PatentApplications is incorporated by reference herein.

While various kinds of surgical stapling instruments and associatedcomponents have been made and used, it is believed that no one prior tothe inventor(s) has made or used the invention described in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention,and, together with the general description of the invention given above,and the detailed description of the embodiments given below, serve toexplain the principles of the present invention.

FIG. 1 depicts a perspective view of an exemplary articulating surgicalstapling instrument;

FIG. 2 depicts a side elevational view of the instrument of FIG. 1;

FIG. 3 depicts a perspective view of an end effector of the instrumentof FIG. 1, with the end effector in a closed configuration;

FIG. 4 depicts a perspective view of the end effector of FIG. 3, withthe end effector in an open configuration;

FIG. 5 depicts an exploded perspective view of the end effector of FIG.3;

FIG. 6 depicts a cross-sectional end view of the end effector of FIG. 3,taken along line 6-6 of FIG. 4;

FIG. 7A depicts a cross-sectional side view of the end effector of FIG.3, taken along line 7-7 of FIG. 4, with the firing beam in a proximalposition;

FIG. 7B depicts a cross-sectional side view of the end effector of FIG.3, taken along line 7-7 of FIG. 4, with the firing beam in a distalposition;

FIG. 8 depicts a perspective view of the end effector of FIG. 3,positioned at tissue and having been actuated once in the tissue;

FIG. 9 depicts a schematic view of an exemplary control circuit for usein the instrument of FIG. 1;

FIG. 10 depicts a perspective view of the handle assembly of theinstrument of FIG. 1, with a housing half and some internal componentsremoved;

FIG. 11 depicts a perspective view of drive assembly components from thehandle assembly of FIG. 10;

FIG. 12 depicts a perspective view of an elongate member from the driveassembly of FIG. 11, coupled with the firing beam;

FIG. 13A depicts a top, plan view of an exemplary alternative shaftassembly that may be incorporated into the instrument of FIG. 1, withthe end effector in a first position;

FIG. 13B depicts a top, plan view of the shaft assembly of FIG. 13A withthe end effector in a second articulated position;

FIG. 14 depicts a perspective view of the proximal end of the shaftassembly of FIG. 13A showing the articulation knob and internalkinematic components;

FIG. 15 depicts a top cross-sectional view of the proximal end of theshaft assembly of FIG. 13A taken along line 15-15 of FIG. 14;

FIG. 16 depicts a top, plan view of the shaft assembly of FIG. 13A in aneutral position;

FIG. 17 depicts a perspective, exploded view of the end effector and thearticulation joint of the shaft assembly of FIG. 13A;

FIG. 18A depicts a top, partially internal view of the articulationjoint of the shaft assembly of FIG. 13A in a first position;

FIG. 18B depicts a top, partially internal view of the articulationjoint of the shaft assembly of FIG. 13A with the first and second armsrotating a first cam member;

FIG. 18C depicts a top, partially internal view of the articulationjoint of the shaft assembly of FIG. 13A with the first and second armsrotating a second cam member and the first cam member further;

FIG. 18D depicts a top, partially internal view of the articulationjoint of the shaft assembly of FIG. 13A with a lock bar resilientlypositioning a lock tooth between teeth of the first cam member and thesecond cam member;

FIG. 18E depicts a top, partially internal view of the articulationjoint of the shaft assembly of FIG. 13A with the first and second armsrotating the first cam member yet even further;

FIG. 19 depicts a top plan, enlarged view of the interface of the cammembers and the lock bar of the shaft assembly of FIG. 13A;

FIG. 20 depicts a perspective, exploded view of locking features of anexemplary alternative articulation joint;

FIG. 21 depicts a top, plan view of the articulation joint incorporatingthe locking features of FIG. 20;

FIG. 22A depicts a side, cross-sectional view of the articulation jointof FIG. 20 taken along line 22-22 of FIG. 21, with a locking member in alocked position;

FIG. 22B depicts a side, cross-sectional view of the articulation jointof FIG. 20 taken along line 22-22 of FIG. 21, with the locking member inan unlocked position;

FIG. 23 depicts exploded view an exemplary alternative helical camassembly;

FIG. 24 depicts a side, cross-sectional view of a helical cam of the camassembly depicted in FIG. 23, taken along line 24-24 of FIG. 23;

FIG. 25A depicts a side, cross-sectional view of an exemplaryalternative articulation joint utilizing the cam assembly of FIG. 23;

FIG. 25B depicts a side, cross-sectional view of the articulation jointof FIG. 25A in an unlocked position;

FIG. 26 depicts a perspective view of an exemplary alternativearticulation joint;

FIG. 27 depicts a perspective view of another exemplary alternativearticulation joint; and

FIG. 28 depicts a cross-sectional side view of an actuation assembly ofthe articulation joint depicted in FIG. 27.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the invention may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presentinvention, and together with the description serve to explain theprinciples of the invention; it being understood, however, that thisinvention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention shouldnot be used to limit the scope of the present invention. Other examples,features, aspects, embodiments, and advantages of the invention willbecome apparent to those skilled in the art from the followingdescription, which is by way of illustration, one of the best modescontemplated for carrying out the invention. As will be realized, theinvention is capable of other different and obvious aspects, all withoutdeparting from the invention. Accordingly, the drawings and descriptionsshould be regarded as illustrative in nature and not restrictive.

I. Exemplary Surgical Stapler

FIG. 1 depicts an exemplary surgical stapling and severing instrument(10) that includes a handle assembly (20), a shaft assembly (30), and anend effector (40). End effector (40) and the distal portion of shaftassembly (30) are sized for insertion, in a nonarticulated state asdepicted in FIG. 1, through a trocar cannula to a surgical site in apatient for performing a surgical procedure. By way of example only,such a trocar may be inserted in a patient's abdomen, between two of thepatient's ribs, or elsewhere. In some settings, instrument (10) is usedwithout a trocar. For instance, end effector (40) and the distal portionof shaft assembly (30) may be inserted directly through a thoracotomy orother type of incision. It should be understood that terms such as“proximal” and “distal” are used herein with reference to a cliniciangripping handle assembly (20) of instrument (10). Thus, end effector(40) is distal with respect to the more proximal handle assembly (20).It will be further appreciated that for convenience and clarity, spatialterms such as “vertical” and “horizontal” are used herein with respectto the drawings. However, surgical instruments are used in manyorientations and positions, and these terms are not intended to belimiting and absolute.

A. Exemplary Handle Assembly and Shaft Assembly

As shown in FIGS. 1-2, handle assembly (20) of the present examplecomprises pistol grip (22), a closure trigger (24), and a firing trigger(26). Each trigger (24, 26) is selectively pivotable toward and awayfrom pistol grip (22) as will be described in greater detail below.Handle assembly (20) further includes an anvil release button (25), afiring beam reverse switch (27), and a removable battery pack (28).These components will also be described in greater detail below. Ofcourse, handle assembly (20) may have a variety of other components,features, and operabilities, in addition to or in lieu of any of thosenoted above. Other suitable configurations for handle assembly (20) willbe apparent to those of ordinary skill in the art in view of theteachings herein.

As shown in FIGS. 1-3, shaft assembly (30) of the present examplecomprises an outer closure tube (32), an articulation section (34), anda closure ring (36), which is further coupled with end effector (40).Closure tube (32) extends along the length of shaft assembly (30).Closure ring (36) is positioned distal to articulation section (34).Closure tube (32) and closure ring (36) are configured to translatelongitudinally relative to handle assembly (20). Longitudinaltranslation of closure tube (32) is communicated to closure ring (36)via articulation section (34). Exemplary features that may be used toprovide longitudinal translation of closure tube (32) and closure ring(36) will be described in greater detail below.

Articulation section (34) is operable to laterally deflect closure ring(36) and end effector (40) laterally away from the longitudinal axis(LA) of shaft assembly (30) at a desired angle (a). End effector (40)may thereby reach behind an organ or approach tissue from a desiredangle or for other reasons. In some versions, articulation section (34)enables deflection of end effector (40) along a single plane. In someother versions, articulation section (34) enables deflection of endeffector along more than one plane. In the present example, articulationis controlled through an articulation control knob (35) which is locatedat the proximal end of shaft assembly (30). Knob (35) is rotatable aboutan axis that is perpendicular to the longitudinal axis (LA) of shaftassembly (30). Closure ring (36) and end effector (40) pivot about anaxis that is perpendicular to the longitudinal axis (LA) of shaftassembly (30) in response to rotation of knob (35). By way of exampleonly, rotation of knob (35) clockwise may cause corresponding clockwisepivoting of closure ring (36) and end effector (40) at articulationsection (34). Articulation section (34) is configured to communicatelongitudinal translation of closure tube (32) to closure ring (36),regardless of whether articulation section (34) is in a straightconfiguration or an articulated configuration.

In some versions, articulation section (34) and/or articulation controlknob (35) are/is constructed and operable in accordance with at leastsome of the teachings of U.S. Pub. No. 2014/0243801, entitled “SurgicalInstrument End Effector Articulation Drive with Pinion and OpposingRacks,” published Aug. 28, 2014, now U.S. Pat. No. 9,186,142, issuedNov. 17, 2015, the disclosure of which is incorporated by referenceherein. Articulation section (34) may also be constructed and operablein accordance with at least some of the teachings of U.S. Pub. No.2015/0374390, entitled “Articulation Drive Features for SurgicalStapler,” published Dec. 31, 2015, the disclosure of which isincorporated by reference herein; and/or in accordance with the variousteachings below. Other suitable forms that articulation section (34) andarticulation knob (35) may take will be apparent to those of ordinaryskill in the art in view of the teachings herein.

As shown in FIGS. 1-2, shaft assembly (30) of the present examplefurther includes a rotation knob (31). Rotation knob (31) is operable torotate the entire shaft assembly (30) and end effector (40) relative tohandle assembly (20) about the longitudinal axis (LA) of shaft assembly(30). In some versions, rotation knob (31) is operable to selectivelylock the angular position of shaft assembly (30) and end effector (40)relative to handle assembly (20) about the longitudinal axis (LA) ofshaft assembly (30). For instance, rotation knob (31) may betranslatable between a first longitudinal position, in which shaftassembly (30) and end effector (40) are rotatable relative to handleassembly (20) about the longitudinal axis (LA) of shaft assembly (30);and a second longitudinal position, in which shaft assembly (30) and endeffector (40) are not rotatable relative to handle assembly (20) aboutthe longitudinal axis (LA) of shaft assembly (30). Of course, shaftassembly (30) may have a variety of other components, features, andoperabilities, in addition to or in lieu of any of those noted above. Byway of example only, at least part of shaft assembly (30) is constructedin accordance with at least some of the teachings of U.S. Pub. No.2014/0239038, entitled “Surgical Instrument with Multi-Diameter Shaft,”published Aug. 28, 2014, now U.S. Pat. No. 9,795,379, issued Oct. 24,2017, the disclosure of which is incorporated by reference herein. Othersuitable configurations for shaft assembly (30) will be apparent tothose of ordinary skill in the art in view of the teachings herein.

B. Exemplary End Effector

As also shown in FIGS. 1-3, end effector (40) of the present exampleincludes a lower jaw (50) and a pivotable anvil (60). Anvil (60)includes a pair of integral, outwardly extending pins (66) that aredisposed in corresponding curved slots (54) of lower jaw (50). Pins (66)and slots (54) are shown in FIG. 5. Anvil (60) is pivotable toward andaway from lower jaw (50) between an open position (shown in FIGS. 2 and4) and a closed position (shown in FIGS. 1, 3, and 7A-7B). Use of theterm “pivotable” (and similar terms with “pivot” as a base) should notbe read as necessarily requiring pivotal movement about a fixed axis.For instance, in the present example, anvil (60) pivots about an axisthat is defined by pins (66), which slide along curved slots (54) oflower jaw (50) as anvil (60) moves toward lower jaw (50). In suchversions, the pivot axis translates along the path defined by slots (54)while anvil (60) simultaneously pivots about that axis. In addition orin the alternative, the pivot axis may slide along slots (54) first,with anvil (60) then pivoting about the pivot axis after the pivot axishas slid a certain distance along the slots (54). It should beunderstood that such sliding/translating pivotal movement is encompassedwithin terms such as “pivot,” “pivots,” “pivotal,” “pivotable,”“pivoting,” and the like. Of course, some versions may provide pivotalmovement of anvil (60) about an axis that remains fixed and does nottranslate within a slot or channel, etc.

As best seen in FIG. 5, lower jaw (50) of the present example defines achannel (52) that is configured to receive a staple cartridge (70).Staple cartridge (70) may be inserted into channel (52), end effector(40) may be actuated, and then staple cartridge (70) may be removed andreplaced with another staple cartridge (70). Lower jaw (50) thusreleasably retains staple cartridge (70) in alignment with anvil (60)for actuation of end effector (40). In some versions, lower jaw (50) isconstructed in accordance with at least some of the teachings of U.S.Pub. No. 2014/0239044, entitled “Installation Features for SurgicalInstrument End Effector Cartridge,” published Aug. 28, 2014, now U.S.Pat. No. 9,808,248, issued Nov. 7, 2017, the disclosure of which isincorporated by reference herein. Other suitable forms that lower jaw(50) may take will be apparent to those of ordinary skill in the art inview of the teachings herein.

As best seen in FIGS. 4-6, staple cartridge (70) of the present examplecomprises a cartridge body (71) and a tray (76) secured to the undersideof cartridge body (71). The upper side of cartridge body (71) presents adeck (73), against which tissue may be compressed when anvil (60) is ina closed position. Cartridge body (71) further defines a longitudinallyextending channel (72) and a plurality of staple pockets (74). A staple(77) is positioned in each staple pocket (74). A staple driver (75) isalso positioned in each staple pocket (74), underneath a correspondingstaple (77), and above tray (76). As will be described in greater detailbelow, staple drivers (75) are operable to translate upwardly in staplepockets (74) to thereby drive staples (77) upwardly through staplepockets (74) and into engagement with anvil (60). Staple drivers (75)are driven upwardly by a wedge sled (78), which is captured betweencartridge body (71) and tray (76), and which translates longitudinallythrough cartridge body (71). Wedge sled (78) includes a pair ofobliquely angled cam surfaces (79), which are configured to engagestaple drivers (75) and thereby drive staple drivers (75) upwardly aswedge sled (78) translates longitudinally through cartridge (70). Forinstance, when wedge sled (78) is in a proximal position as shown inFIG. 7A, staple drivers (75) are in downward positions and staples (77)are located in staple pockets (74). As wedge sled (78) is driven to thedistal position shown in FIG. 7B by a translating knife member (80),wedge sled (78) drives staple drivers (75) upwardly, thereby drivingstaples (77) out of staple pockets (74) and into staple forming pockets(64). Thus, staple drivers (75) translate along a vertical dimension aswedge sled (78) translates along a horizontal dimension.

It should be understood that the configuration of staple cartridge (70)may be varied in numerous ways. For instance, staple cartridge (70) ofthe present example includes two longitudinally extending rows of staplepockets (74) on one side of channel (72); and another set of twolongitudinally extending rows of staple pockets (74) on the other sideof channel (72). However, in some other versions, staple cartridge (70)includes three, one, or some other number of staple pockets (74) on eachside of channel (72). In some versions, staple cartridge (70) isconstructed and operable in accordance with at least some of theteachings of U.S. Pub. No. 2014/0239042, entitled “Integrated TissuePositioning and Jaw Alignment Features for Surgical Stapler,” publishedAug. 28, 2014, now U.S. Pat. No. 9,517,065, issued Dec. 13, 2016, thedisclosure of which is incorporated by reference herein. In addition orin the alternative, staple cartridge (70) may be constructed andoperable in accordance with at least some of the teachings of U.S. Pub.No. 2014/0239044, entitled “Installation Features for SurgicalInstrument End Effector Cartridge,” published Aug. 28, 2014, now U.S.Pat. No. 9,808,248, issued Nov. 7, 2017, the disclosure of which isincorporated by reference herein. Other suitable forms that staplecartridge (70) may take will be apparent to those of ordinary skill inthe art in view of the teachings herein.

As best seen in FIG. 4, anvil (60) of the present example comprises alongitudinally extending channel (62) and a plurality of staple formingpockets (64). Channel (62) is configured to align with channel (72) ofstaple cartridge (70) when anvil (60) is in a closed position. Eachstaple forming pocket (64) is positioned to lie over a correspondingstaple pocket (74) of staple cartridge (70) when anvil (60) is in aclosed position. Staple forming pockets (64) are configured to deformthe legs of staples (77) when staples (77) are driven through tissue andinto anvil (60). In particular, staple forming pockets (64) areconfigured to bend the legs of staples (77) to secure the formed staples(77) in the tissue. Anvil (60) may be constructed in accordance with atleast some of the teachings of U.S. Pub. No. 2014/0239042, entitled“Integrated Tissue Positioning and Jaw Alignment Features for SurgicalStapler,” published Aug. 28, 2014, now U.S. Pat. No. 9,517,065, issuedDec. 13, 2016, at least some of the teachings of U.S. Pub. No.2014/0239036, entitled “Jaw Closure Feature for End Effector of SurgicalInstrument,” published Aug. 28, 2014, now U.S. Pat. No. 9,839,421,issued Dec. 12, 2017; and/or at least some of the teachings of U.S. Pub.No. 2014/0239037, entitled “Staple Forming Features for SurgicalStapling Instrument,” published Aug. 28, 2014, the disclosure of whichis incorporated by reference herein. Other suitable forms that anvil(60) may take will be apparent to those of ordinary skill in the art inview of the teachings herein.

In the present example, a knife member (80) is configured to translatethrough end effector (40). As best seen in FIGS. 5 and 7A-7B, knifemember (80) is secured to the distal end of a firing beam (82), whichextends through a portion of shaft assembly (30). As best seen in FIGS.4 and 6, knife member (80) is positioned in channels (62, 72) of anvil(60) and staple cartridge (70). Knife member (80) includes a distallypresented cutting edge (84) that is configured to sever tissue that iscompressed between anvil (60) and deck (73) of staple cartridge (70) asknife member (80) translates distally through end effector (40). Asnoted above and as shown in FIGS. 7A-7B, knife member (80) also driveswedge sled (78) distally as knife member (80) translates distallythrough end effector (40), thereby driving staples (77) through tissueand against anvil (60) into formation. Various features that may be usedto drive knife member (80) distally through end effector (40) will bedescribed in greater detail below.

In some versions, end effector (40) includes lockout features that areconfigured to prevent knife member (80) from advancing distally throughend effector (40) when a staple cartridge (70) is not inserted in lowerjaw (50). In addition or in the alternative, end effector (40) mayinclude lockout features that are configured to prevent knife member(80) from advancing distally through end effector (40) when a staplecartridge (70) that has already been actuated once (e.g., with allstaples (77) deployed therefrom) is inserted in lower jaw (50). By wayof example only, such lockout features may be configured in accordancewith at least some of the teachings of U.S. Pub. No. 2014/0239041,entitled “Lockout Feature for Movable Cutting Member of SurgicalInstrument,” published Aug. 28, 2014, now U.S. Pat. No. 9,717,497,issued Aug. 1, 2017, the disclosure of which is incorporated byreference herein; and/or at least some of the teachings of U.S. Pub. No.2015/0374373, entitled “Method of Using Lockout Features for SurgicalStapler Cartridge,” published Dec. 31, 2015, the disclosure of which isincorporated by reference herein. Other suitable forms that lockoutfeatures may take will be apparent to those of ordinary skill in the artin view of the teachings herein. Alternatively, end effector (40) maysimply omit such lockout features.

C. Exemplary Actuation of Anvil

In the present example, anvil (60) is driven toward lower jaw (50) byadvancing closure ring (36) distally relative to end effector (40).Closure ring (36) cooperates with anvil (60) through a camming action todrive anvil (60) toward lower jaw (50) in response to distal translationof closure ring (36) relative to end effector (40). Similarly, closurering (36) may cooperate with anvil (60) to open anvil (60) away fromlower jaw (50) in response to proximal translation of closure ring (36)relative to end effector (40). By way of example only, closure ring (36)and anvil (60) may interact in accordance with at least some of theteachings of U.S. Pub. No. 2014/0239036, entitled “Jaw Closure Featurefor End Effector of Surgical Instrument,” published Aug. 28, 2014, nowU.S. Pat. No. 9,839,421, issued Dec. 12, 2017, the disclosure of whichis incorporated by reference herein; and/or in accordance with at leastsome of the teachings of U.S. Pub. No. 2015/0374361, entitled “JawOpening Feature for Surgical Stapler,” published Dec. 31, 2015, thedisclosure of which is incorporated by reference herein. Exemplaryfeatures that may be used to provide longitudinal translation of closurering (36) relative to end effector (40) will be described in greaterdetail below.

As noted above, handle assembly (20) includes a pistol grip (22) and aclosure trigger (24). As also noted above, anvil (60) is closed towardlower jaw (50) in response to distal advancement of closure ring (36).In the present example, closure trigger (24) is pivotable toward pistolgrip (22) to drive closure tube (32) and closure ring (36) distally.Various suitable components that may be used to convert pivotal movementof closure trigger (24) toward pistol grip (22) into distal translationof closure tube (32) and closure ring (36) relative to handle assembly(20) will be apparent to those of ordinary skill in the art in view ofthe teachings herein. When closure trigger (24) reaches a fully pivotedstate, such that anvil (60) is in a fully closed position relative tolower jaw (50), locking features in handle assembly (20) lock theposition of trigger (24) and closure tube (32), thereby locking anvil(60) in a fully closed position relative to lower jaw (50). Theselocking features are released by actuation of anvil release button (25).Anvil release button (25) is configured and positioned to be actuated bythe thumb of the operator hand that grasps pistol grip (22). In otherwords, the operator may grasp pistol grip (22) with one hand, actuateclosure trigger (24) with one or more fingers of the same hand, and thenactuate anvil release button (25) with the thumb of the same hand,without ever needing to release the grasp of pistol grip (22) with thesame hand. Other suitable features that may be used to actuate anvil(60) will be apparent to those of ordinary skill in the art in view ofthe teachings herein.

D. Exemplary Actuation of Firing Beam

In the present example, instrument (10) provides motorized control offiring beam (82). FIGS. 9-12 show exemplary components that may be usedto provide motorized control of firing beam (82). In particular, FIG. 9shows an exemplary control circuit (100) that may be used to power anelectric motor (102) with electric power from a battery pack (28) (alsoshown in FIGS. 1-2). Electric motor (102) is operable to translatefiring beam (82) longitudinally as will be described in greater detailbelow. It should be understood that the entire control circuit (100),including motor (102) and battery pack (28), may be housed within handleassembly (20). FIG. 9 shows firing trigger (26) as an open switch,though it should be understood that this switch is closed when firingtrigger (26) is actuated. Circuit (100) of this example also includes asafety switch (106) that must be closed in order to complete circuit(100), though it should be understood that safety switch (106) is merelyoptional. Safety switch (106) may be closed by actuating a separatebutton, slider, or other feature on handle assembly (20). Safety switch(106) may also provide a mechanical lockout of firing trigger (26), suchthat firing trigger (26) is mechanically blocked from actuation untilsafety switch (106) is actuated.

Circuit (100) of the present example also includes a lockout switch(108), which is configured to be closed by default but is automaticallyopened in response to a lockout condition. By way of example only, alockout condition may include one or more of the following: the absenceof a cartridge (70) in lower jaw (50), the presence of a spent (e.g.,previously fired) cartridge (70) in lower jaw (50), an insufficientlyclosed anvil (60), a determination that instrument (10) has been firedtoo many times, and/or any other suitable conditions. Various sensors,algorithms, and other features that may be used to detect lockoutconditions will be apparent to those of ordinary skill in the art inview of the teachings herein. Similarly, other suitable kinds of lockoutconditions will be apparent to those of ordinary skill in the art inview of the teachings herein. It should be understood that circuit (100)is opened and thus motor (102) is inoperable when lockout switch (108)is opened. A lockout indicator (110) (e.g., an LED, etc.) is operable toprovide a visual indication of the status of lockout switch (108). Byway of example only, lockout switch (108), lockout indicator (110), andassociated components/functionality may be configured in accordance withat least some of the teachings of U.S. Pat. No. 7,644,848, entitled“Electronic Lockouts and Surgical Instrument Including Same,” issuedJan. 12, 2010, the disclosure of which is incorporated by referenceherein.

Once firing beam (82) reaches a distal-most position (e.g., at the endof a cutting stroke), an end-of-stroke switch (112) is automaticallyswitched to a closed position, reversing the polarity of the voltageapplied to motor (102). This reverses the direction of rotation of motor(102), it being understood that the operator will have released firingtrigger (26) at this stage of operation. In this operational state,current flows through a reverse direction indicator (114) (e.g., an LED,etc.) to provide a visual indication to the operator that motor (102)rotation has been reversed. In the present example, and as best seen inFIG. 12, a switch actuation arm (134) extends laterally from rack member(130), and is positioned to engage end-of-stroke switch (112) whenfiring beam (82) reaches a distal-most position (e.g., after tissue (90)has been severed and staples (77) have been driven into tissue (90)).Various other suitable ways in which end-of-stroke switch (112) may beautomatically switched to a closed position when firing beam (82)reaches a distal-most position will be apparent to those of ordinaryskill in the art in view of the teachings herein. Similarly, varioussuitable forms that reverse direction indicator (114) may take will beapparent to those of ordinary skill in the art in view of the teachingsherein.

Handle assembly (20) of the present example also includes a manualreturn switch (116), which is also shown in circuit (100). In thepresent example, return switch is activated by actuating reverse switch(27), which is shown on handle assembly (20) in FIG. 1. Manual returnswitch (116) may provide functionality similar to end-of-stroke switch(112), reversing the polarity of the voltage applied to motor (102) tothereby reverse the direction of rotation of motor (102). Again, thisreversal may be visually indicated through reverse direction indicator(114). In some versions, handle assembly (20) further includes amechanical return feature that enables the operator to manually reversefiring beam (82) and thereby retract firing beam (82) mechanically. Inthe present example, this manual return feature comprises a lever thatis covered by a removable panel (21) as shown in FIG. 1. Manual returnswitch (116) and the mechanical return feature are each configured toact as a “bailout” feature, enabling the operator to quickly beginretracting firing beam (82) proximally during a firing stroke. In otherwords, manual return switch (116) or the mechanical return feature maybe actuated when firing beam (82) has only been partially advanceddistally.

In some versions, one or more of switches (26, 106, 108, 112, 116) arein the form of microswitches. Other suitable forms will be apparent tothose of ordinary skill in the art in view of the teachings herein. Inaddition to or in lieu of the foregoing, at least part of circuit (100)may be configured in accordance with at least some of the teachings ofU.S. Pat. No. 8,210,411, entitled “Motor-Driven Surgical Instrument,”issued Jul. 3, 2012, the disclosure of which is incorporated byreference herein.

FIG. 10 shows motor (102) positioned within pistol grip (22) of handleassembly (20). Alternatively, motor (102) may be positioned elsewherewithin handle assembly (20). Motor (102) has a drive shaft (120) that iscoupled with a gear assembly (122). Thus, when motor (102) is activated,drive shaft (120) actuates gear assembly (122). As shown in FIG. 11,gear assembly (122) is in communication with a drive gear (124), whichmeshes with an idler pinion (126). Pinion (126) is disposed on a shaft(128) that is supported within handle assembly (20) and that is orientedparallel to drive shaft (120) of motor (102). Pinion (126) is furtherengaged with a rack member (130). In particular, pinion (126) mesheswith teeth (132) at the proximal end of rack member (130). Rack member(130) is slidably supported in handle assembly (20). It should beunderstood from the foregoing that, when motor (102) is activated, thecorresponding rotation of drive shaft (120) is communicated to pinion(126) via gear assembly (122), and the corresponding rotation of pinion(126) is converted to translation of rack member (130) by teeth (132).As shown in FIGS. 10-12, an elongate member (136) extends distally fromrack member (130). As shown in FIG. 12, a coupling member (138) joinsfiring beam (82) with elongate member (136). Rack member (130), elongatemember (136), coupling member (138), firing beam (82), and knife member(80) all translate together relative to handle assembly (20) in responseto activation of motor (102). In other words, activation of motor (102)ultimately causes firing beam (82) to translate longitudinally, thedirection of such translation depending on the direction of rotation ofdrive shaft (120).

It should be understood that a distal portion of elongate member (136),coupling member (138), and firing beam (82) extend through shaftassembly (30). A portion of firing beam (82) also extends througharticulation section (34). In some versions, rack member (130), elongatemember (136), and coupling member (138) are all substantially straightand rigid; while firing beam (82) has sufficient flexibility to bend atarticulation section (34) and translate longitudinally througharticulation section (34) when articulation section (34) is in a bent orarticulated state.

In addition to or in lieu of the foregoing, the features operable todrive firing beam (82) may be configured in accordance with at leastsome of the teachings of U.S. Pat. No. 8,453,914, the disclosure ofwhich is incorporated by reference herein. Other suitable components,features, and configurations for providing motorization of firing beam(82) will be apparent to those of ordinary skill in the art in view ofthe teachings herein. It should also be understood that some otherversions may provide manual driving of firing beam (82), such that amotor may be omitted. By way of example only, firing beam (82) may beactuated in accordance with at least some of the teachings of any otherreference cited herein.

FIG. 8 shows end effector (40) having been actuated through a singlestroke through tissue (90). As shown, cutting edge (84) (obscured inFIG. 8) has cut through tissue (90), while staple drivers (75) havedriven two alternating rows of staples (77) through the tissue (90) oneach side of the cut line produced by cutting edge (84). Staples (77)are all oriented substantially parallel to the cut line in this example,though it should be understood that staples (77) may be positioned atany suitable orientations. In the present example, end effector (40) iswithdrawn from the trocar after the first stroke is complete, the spentstaple cartridge (70) is replaced with a new staple cartridge (70), andend effector (40) is then again inserted through the trocar to reach thestapling site for further cutting and stapling. This process may berepeated until the desired amount of cuts and staples (77) have beenprovided. Anvil (60) may need to be closed to facilitate insertion andwithdrawal through the trocar; and anvil (60) may need to be opened tofacilitate replacement of staple cartridge (70).

It should be understood that cutting edge (84) may sever tissuesubstantially contemporaneously with staples (77) being driven throughtissue during each actuation stroke. In the present example, cuttingedge (84) just slightly lags behind driving of staples (77), such that astaple (47) is driven through the tissue just before cutting edge (84)passes through the same region of tissue, though it should be understoodthat this order may be reversed or that cutting edge (84) may bedirectly synchronized with adjacent staples (77). While FIG. 8 shows endeffector (40) being actuated in two layers (92, 94) of tissue (90), itshould be understood that end effector (40) may be actuated through asingle layer of tissue (90) or more than two layers (92, 94) of tissue.It should also be understood that the formation and positioning ofstaples (77) adjacent to the cut line produced by cutting edge (84) maysubstantially seal the tissue at the cut line, thereby reducing orpreventing bleeding and/or leaking of other bodily fluids at the cutline. Furthermore, while FIG. 8 shows end effector (40) being actuatedin two substantially flat, apposed planar layers (92, 94) of tissue, itshould be understood that end effector (40) may also be actuated acrossa tubular structure such as a blood vessel, a section of thegastrointestinal tract, etc. FIG. 8 should therefore not be viewed asdemonstrating any limitation on the contemplated uses for end effector(40). Various suitable settings and procedures in which instrument (10)may be used will be apparent to those of ordinary skill in the art inview of the teachings herein.

It should also be understood that any other components or features ofinstrument (10) may be configured and operable in accordance with any ofthe various references cited herein. Additional exemplary modificationsthat may be provided for instrument (10) will be described in greaterdetail below. Various suitable ways in which the below teachings may beincorporated into instrument (10) will be apparent to those of ordinaryskill in the art. Similarly, various suitable ways in which the belowteachings may be combined with various teachings of the references citedherein will be apparent to those of ordinary skill in the art. It shouldalso be understood that the below teachings are not limited toinstrument (10) or devices taught in the references cited herein. Thebelow teachings may be readily applied to various other kinds ofinstruments, including instruments that would not be classified assurgical staplers. Various other suitable devices and settings in whichthe below teachings may be applied will be apparent to those of ordinaryskill in the art in view of the teachings herein.

II. Exemplary Alternative Shaft Assembly

It will be appreciated that as a user urges instrument (10) into asurgical region, it may be desirable to approach the tissue to beclamped, stapled, or cut, from a particular angle. For instance, onceend effector (40) of instrument (10) is inserted through a trocar,thoracotomy, or other passageway for entering a surgical area, thetissue that the user wishes to target may be positioned out of reach orat an askew angle in relation to end effector (40) that is aligned withlongitudinal axis (LA) of shaft assembly (30). Thus, it may be desirablefor portions of instrument (10), such as end effector (40), toarticulate relative to longitudinal axis (LA) of shaft assembly (30) atan angle (a) (as seen in phantom in FIG. 1) such that the user canposition anvil (60) and lower jaw (50) of end effector (40) to squarelyor perpendicularly clamp against a vessel or other tissue. It willfurther be understood that articulating end effector (40) to squarelyposition end effector (40) against tissue may promote full seating andclamping of the tissue prior to cutting and stapling tissue. In additionto articulating, it may be desirable for end effector (40) to beselectively locked in a straight or articulated position such that aconstant manual bias by the user is not necessary to prevent endeffector (40) from pivoting or bending at articulation section (34). Itmay also be desirable to automatically lock upon articulation, withoutrequiring actuations of a separate articulation locking feature.

FIG. 13A depicts an exemplary alternative shaft assembly (200) that maybe readily incorporated with instrument (10) of FIG. 1. Shaft assembly(200) provides articulation and selective locking of articulationangles, as will be described in greater detail below. Shaft assembly(200) of the present example comprises a rotation knob (231),articulation control knob (235), and an end effector (240). Shaftassembly (200) also comprises end effector (240) positioned distally inrelation to a closure tube (232). End effector (240) includes anarticulation joint (234) which allows end effector (240) to articulatelaterally as will be described in further detail below. End effector(240) is substantially identical to end effector (40) of FIG. 1 exceptas otherwise described below.

Rotation knob (231) may be rotatably coupled with handle assembly (20)of FIG. 1 or any other suitable component (e.g., robotic controlinterface, etc.). Rotation knob (231) is operable to rotate shaftassembly (200) (including articulation control knob (235) and endeffector (240)) about the longitudinal axis (LA) defined by shaftassembly (200), relative to handle portion (20) (or relative to whateverelse rotation knob (231) is rotatably coupled with). This may be usefulin positioning end effector (240) at a desired angular orientation aboutthe longitudinal axis (LA).

A. Exemplary Articulation Control Features

Articulation control knob (235) is partially contained within anarticulation control knob casing (237). Casing (237) leads to closuretube (232). FIGS. 13A-B show shaft assembly (200) and an exemplarymovement of end effector (240) in response to turning of articulationcontrol knob (235). FIG. 13A shows articulation control knob (235) in afirst position where articulation control knob (235) and end effector(240) are both generally aligned along the longitudinal axis (LA) ofshaft assembly (200). The user may then manually rotate articulationcontrol knob (235) clockwise as seen in FIG. 13B to a second position.In response to the rotation of articulation control knob (235), endeffector (240) pivots or bends at articulation joint (234). as seen inFIG. 16B, to an articulation angle (a). In the present example, endeffector (240) articulates generally in the direction of the rotation ofarticulation control knob (235), though it will be understood that endeffector (240) may be configured to bend in the opposite direction ofthe rotation of articulation control knob (235). In other words, whenarticulation control knob (235) is rotated clockwise, end effector (240)laterally pivots clockwise as shown in FIG. 13B but could be configuredin some versions to pivot counter clockwise. FIG. 13B shows end effector(240) laterally pivoting clockwise slightly. It will be understood thatarticulation control knob (235) may be rotated further to cause endeffector (240) to laterally articulate further at articulation joint(234) to any suitable angle (a). For instance, end effector (240) maypivot until an approximately 90° angle is formed across articulationjoint (234). In some versions, end effector (240) may be operable topivot even further such that end effector (240) forms an acute angle inrelation to tube (232). Other suitable variations of end effector (240)pivoting will be apparent to one of ordinary skill in the art in view ofthe teachings herein. It should also be understood that articulationcontrol knob (235) may define the same angle with the longidunal axis(LA) as the articulation angle (a) defined between end effector (240)and the longidunal axis (LA). Such complementary angling may provide theoperator with visual feedback exterior to the patient, indicating thearticulation angle (a) of end effector (240).

The mechanics of the articulation of end effector (240) will bediscussed in further detail below. It will be appreciated thatarticulation control knob (235) may be rotated in the counter clockwisedirection to cause end effector (240) to articulate in a counterclockwise manner. Thus, depending on the desired direction and/or amountof articulation of end effector (240), the user can simply rotatearticulation control knob (235) of varying degrees in the direction thatthe user wishes end effector (240) to articulate to cause varyingdegrees of articulation of end effector (240).

FIG. 14 shows articulation control knob (235) with casing (237) removedto better show the inner workings of articulation control knob (235).Articulation control knob (235) is in communication with an articulationpinion (250). Articulation pinion (250) is in communication with a firstrack (252) and a second rack (256). First rack (252) is in communicationwith a first arm (242) through a first intermediate block (254), whereassecond rack (256) is in communication with a second arm (244) through asecond intermediate block (258). Arms (242, 244) are substantiallyparallel to each other in the present example. In particular, theproximal portions of arms (242, 244) (as shown in FIG. 18 and theportions of arms (242, 244) that extend through shaft assembly (200) areparallel to each other, though the proximal ends of arms (242, 244)flare slightly outwardly. Since arms (242, 244) are parallel to eachother along nearly their entire length (i.e., except for the distal-mostportions), arms (242, 244) may be readily recognized by those skilled inthe art as being “substantially parallel” to each other.

Articulation control knob (235) is unitarily coupled to articulationpinion (250). As a result, when the user turns articulation control knob(235), articulation pinion (250) rotates together with articulationcontrol knob (235). As articulation pinion (250) rotates, articulationpinion translates first rack (252) and second rack (256) accordingly inopposing directions. For instance, as seen in FIG. 15, articulationpinion (250) is in communication with first rack (252) and second rack(256) such that if articulation pinion (250) rotates clockwise, firstrack (252) retracts proximally away from end effector (240) whereassecond rack (256) advances distally toward end effector (240).Furthermore, when articulation pinion (250) rotates counter-clockwise,first rack (252) advances distally toward end effector (240) and secondrack (256) retracts proximally away from end effector (240). As firstrack (252) advances and retracts, first arm (242) advances and retractsin a similar manner. Similarly, as second rack (256) advances andretracts, second arm (244) also advances and retracts with second rack(256). Thus, rotating actuation control knob (235), which is connectedto articulation pinion (250), causes first arm (242) and second arm(244) to move back and forth with first rack (252) and second rack(256). Movement of first arm (242) and second arm (244) is operable tocause movement of other components in end effector (240), as will bediscussed in greater detail below.

FIG. 16 shows a larger view of end effector (240), including anvil(260). First arm (242) and second arm (244) are in communication with afirst cam member (330), which is pivotally disposed about a pin (379).As a result, advancing and retracting first arm (242) and second arm(244) causes first cam member (370) to rotate about cam holding pin(379), as will be described in further detail below.

FIG. 17 shows an exploded view of articulation joint (234). End effector(240) is disposed at the distal end of articulation joint (234). Endeffector (240) comprises an anvil (260) and lower jaw (268). It will beappreciated that end effector (240) is substantially similar to endeffector (40) of FIG. 1. Similar to lower jaw (50) of end effector (40),lower jaw (268) may receive a staple cartridge (not shown) which may besubstantially similar to staple cartridge (70). Additionally, similar toend effector (40) as described above, anvil (260) is driven toward lowerjaw (268) by advancing a closure ring (236) distally relative to endeffector (240). Closure ring (236) is driven longitudinally relative toend effector (240) based on translation of closure tube (232).Translation of closure tube (232) is communicated to closure ring (236)via articulation joint (234). Functionally, anvil (260) and lower jaw(268) are substantially similar to anvil (60) and lower jaw (50) of endeffector (40) with anvil (260) and lower jaw (268) working cooperativelyto contemporaneously sever and staple tissue as shown in FIG. 8 anddescribed above.

Articulation joint (234) comprises first cam member (330), second cammember (331), cam holding body (376), joint base (372), a lock bar (262)and a spring (364). First arm (242) distally terminates in a first hook(245), while second arm (244) distally terminates in a second hook(246). Hooks (245, 246) are in communication with cam openings (360) offirst cam member (330). As a result, when first arm (242) adavancestoward end effector (240) and second arm (244) retracts, first cammember (330) rotates counter clockwise about holding pin (379). Whenfirst arm (242) instead retracts and second arm (244) advances towardend effector (240), first cam member (330) rotates clockwise aboutholding pin (379). Thus, as arms (242, 244) push and pull on camopenings (360) via hooks (245, 246) in an opposing fashion, first cammember (330) rotates accordingly as just described.

First cam member (330) is stacked on a second cam member (331). Secondcam member (331) and cam holding pin (379) are unitary features of camholding body (376). In some versions, second cam member (331) may beseparately constructed and fixedly coupled with cam holding body (376),such that as second cam member (331) rotates, cam holding body (376)rotates. Cam holding pin (379) is coaxially aligned with base opening(377) of joint base (372) along a pivot axis (380). Thus, first cammember (330) is rotatable about pivot axis (380), relative to second cammember (231) and cam holding body (376). Lock bar (262) is in selectivecommunication with first cam member (330) and second cam member (331),which will be described in greater detail below. Lock bar (262) isfurther in communication with spring (364), which distally biases lockbar (262). Joint base (372) is shaped to provide a seat and/or channelfor lock bar (262) to advance in. Lock bar (262) further includes a pairof bosses (387) operable to engage joint base (372) to restrict distalmotion of lock bar (262).

B. Exemplary Articulation of the Shaft Assembly

As discussed above, actuating articulation control knob (235) causesopposing advancement and retraction of arms (242, 244). It will beunderstood that this motion of arms (242, 244) rotates first cam member(330) about cam holding pin (279). As a result of rotating first cammember (330), second cam member (331) rotates with cam holding body(376. Thus, articulation joint (234) articulates, thereby pivoting endeffector (240) at articulation joint (234). In particular, cam holdingpin (379) and base opening (374) define a pivot axis (380), which isgenerally perpendicular to the longitudinal axis (LA) as noted above.End effector (240) pivots about pivot axis (380) in response to therotation of first cam member (330), which drives second cam member (331)as will be discussed below. In other words, pivot axis (380) serves asan axis for articulation of end effector (240) relative to shaftassembly (200). FIGS. 18A-E show the details of rotating first cammember (330) to drive the articulation of end effector (240).

FIG. 18A shows articulation joint (234) in a first position. Lock bar(262) is distally biased to engage second cam member (331). Inparticular, the distal end of lock bar (262) comprises a lock tooth(336) that fits between first cam teeth (333) and second cam teeth (335)and abuts second cam member (331), which can be seen in further detailin FIG. 19. As a result of the distal bias provided by spring (364),lock tooth (336) acts as a positive lock and thus maintains therotational position of second cam member (331). By maintaining therotational position of second cam member (331), lock bar (262) maintainsthe angular position of end effector (240) about pivot axis (380),thereby maintaining any articulation angle (a). First cam member (330)comprises a pair of cam wings (338, 339), and cam holding body (376)comprises a pair of bosses (371, 373). Bosses (371, 373) are unitaryfeatures of second cam member (331), such that as bosses (371, 373)rotate, second cam member (331) also rotates. It will be appreciatedthat in the first position of FIG. 18A, cam wings (338, 339) and bosses(371, 373) are not in contact. The interaction involving contact betweencam wings (338, 339) and bosses (371, 373) will be described in furtherdetail below with reference to FIGS. 18B-E. During a surgical operation,the user may guide shaft assembly (200) through a passageway (e.g.,trocar, thoracotomy, etc.) to reach the surgical area with end effector(240) in a straightened position as shown in FIG. 18A.

FIG. 19 shows an enlarged view of lock tooth (336) in the position shownin FIG. 18A. As can be seen, lock tooth (336) has generally straightparallel sides (386) that are configured to fit between first cam teeth(333) and second cam teeth (335). The distal end of lock tooth (336) hasa rounded tip (385) with angled sides (381) leading to parallel sides(386). Each tooth (335) of second cam teeth (335) comprises generallystraight parallel sides (383) and angled sides (384). Parallel sides(383) are configured to engage parallel sides (386) of lock tooth (336)to prevent lock tooth (336) from riding along second cam teeth (335)without assistance from first cam member (330). This engagement betweenat least one side (383) and at least one side (386) also prevents camholding body (376) from rotating about pivot axis (380), therebypreventing end effector (240) from pivoting at articulation joint (234).

Once first cam member (330) rotates as shown in FIGS. 18B-C and as willbe described in greater detail below, a triangular tooth (333) of firstcam member (330) will cam against angled sides (381), and will therebydive lock bar (262) proximally in response to first cam (330) rotating.It should be understood that tooth (333) may have a variety of differentshapes other than triangular. Some exemplary alternative shapes will bedescribed in greater detail below, while others will be apparent tothose of ordinary skill in the art in view of the teachings herein. Locktooth (336) moves proximally sufficiently such that angled sides (381)of lock tooth (336) can eventually engage and ride along angled sides(384) of second cam teeth (335) as first cam member (330) continues torotate and as second cam member (331) rotates. This provides furthercamming action to drive lock bar (262) proximally. Once lock tooth (336)traverses angled sides (384) of second cam teeth (335), then lock tooth(336) returns distally to a position between the next pair of first camteeth (333) and second cam teeth (335) similar to the positioning shownin FIG. 19. For illustrative purposes, advancing lock tooth (336)between one set of first cam teeth (333) and second cam teeth (335) maybe considered one articulation increment. As lock tooth (336) distallyadvances, lock tooth (336) strikes second cam member (331) betweensecond cam teeth (335). It will be understood that lock tooth (336) neednot necessarily extend far enough to strike second cam member (331). Forinstance, lock tooth (336) may only extend distally such that parallelsides (383) prevent lock tooth (336) from riding along second cam member(331) without assistance from first cam teeth (333). In the illustratedversion, bosses (387) engage joint base (382) to prevent further distalmotion of lock bar (262).

As noted above, the operator may wish to pivot end effector (240) atarticulation joint (234) to better position end effector (240) inrelation to targeted tissue. FIG. 18B shows a second stage of actuationfor articulation joint (234) to move to in response to turningarticulation control knob (235) shown in FIG. 14. In the illustratedversion, the user has turned articulation knob (235) counter clockwise,which rotates articulation pinion (250) as well. As articulation pinion(250) rotates counter clockwise, first rack (252) moves distally andsecond rack (256) moves proximally in relation to end effector (240).Accordingly, first arm (242) and second arm (244) as shown in FIG. 18Bmove such that first arm (242) advances toward end effector (240) andsecond arm (244) retracts away from end effector (240). It will beappreciated that the distal portions of first arm (242) and second arm(244) of the illustrated version are not positioned parallel in relationto each other. Instead, first arm (242) and second arm (244) areobliquely angled in relation to each other, though it will be understoodthat first arm (242) and second arm (244) could be positioned parallelto each other.

Movement of arms (242, 244) as seen in FIG. 18B causes first cam member(330) to rotate counter clockwise about pivot axis (380). As first cammember (330) rotates, two actions occur in a generally simultaneousmanner. First, cam teeth (330) have a triangular shape that urges lockbar (262) proximally away from end effector (240) through a cammingaction as a result of first cam teeth (333) engaging angled sides (381).Again, teeth (333) may have a variety of different shapes other thantriangular. Spring (364) compresses to accommodate proximal motion oflock bar (262). As a result, rounded tip (385) moves proximallysufficient to traverse parallel sides (383). Additionally, cam wings(338, 339) rotate counter clockwise with first cam member (330). As aresult of the rotation, cam wing (339) removes gap (361) between boss(373) and engages boss (373). Meanwhile, cam wing (338) movesrotationally away from boss (371). It will be understood that whilefirst cam member (330) and lock bar (262) have moved in response to themovement of arms (242, 244) during the transition from the configurationshown in FIG. 18A to the configuration shown in FIG. 18B, second cammember (331) and accordingly end effector (240) have not yet moved.Thus, end effector (240) remains in a straight orientation at thisstage.

FIG. 18C shows a third stage of actuation of articulation joint (234).It will be understood that the user continues to rotate articulationcontrol knob (235) in an effort to articulate end effector (240). Arms(242, 244) continue to move such that first arm (242) moves distally andsecond arm (244) moves proximally. Movement of arms (242, 244) continuesto rotate first cam member (330), which causes cam wing (339) torotationally move further thereby urging boss (373) to rotationally moveas well. Since boss (273) is unitary with second cam member (331),second cam member (331) begins to rotate. As second cam member rotates(331), lock bar (262) moves further proximally as a result of angledsides (384) camming against angled sides (381) of lock tooth (336).Thus, lock tooth (236) rides along second cam teeth (335). Second cammember (331) rotates until tip (388) of second cam member (331) engagesrounded tip (385). Second cam teeth (335) have parallel sides (383) suchthat angled edges (381) of lock tooth (336) can engage angled sides(284) only after first cam teeth (333) urges lock tooth (336) proximallysuch that rounded tip (385) traverses parallel sides (383). Prior toriding along first cam teeth (333), lock tooth (336) is generally unableto ride along second cam teeth (335) due to parallel sides (383)engaging parallel sides (386). It will further be appreciated that aslock tooth (336) rides along angled sides (384), lock tooth (336)disengages first cam teeth (333). As also seen in FIG. 18C, lock bar(262) and lock tooth (336) have moved to a proximal most position withjust second cam teeth tip (388) being in contact with lock tooth (336).Also as a result of rotation of second cam member (331), cam holdingbody (376) and accordingly, closure ring (236), which leads to endeffector (240), articulate in a counter clockwise direction.

FIG. 18D shows a fourth stage of actuation for articulation joint (234).Once again, it will be understood that user is continuing to rotatearticulation control knob (235) in an effort to cause furtherarticulation of end effector (240). Arms (242, 244) continue to movesuch that first arm (242) moves distally further and second arm (244)moves proximally further. Movement of arms (242, 244) continues torotate first cam member (330), which causes cam wing (339) to push boss(373) rotationally further. Lock tooth (336) continues to ride alongsecond cam teeth (335) until the distal bias caused by spring (364)urges lock bar (262) into the position shown in FIG. 18D. It will beappreciated that when lock bar (262) snaps into the position shown inFIG. 18D, an audible click or snap may be heard or felt. As a result,the user receives audible and/or tactile confirmation that lock tooth(336) has moved from between one set of cam teeth (333, 335) to anotheror otherwise has rotated by a single articulation increment. When in theposition shown in FIG. 18D, first cam member (330) stops rotating andlock tooth (236) fits between cam teeth (333, 335). Closure ring (236)and accordingly end effector (240) stop articulating. A positive lockhas formed because any rotational motion of second cam member (331)urged by transverse forces on end effector (240) would result inparallel sides (386) engaging parallel sides (383) and stopping anyfurther rotation of second cam member (331), which locks thearticulation of end effector (240). It should be understood that thetransition from the configuration shown in FIG. 18A to the configurationshown in FIG. 18D represents articulation through one articulationincrement, or increment of articulation motion, in which the distance isdefined generally by the spaces between second cam teeth (335).

It will be understood that in the position shown in FIG. 18D, endeffector (240) has articulated thereby providing the user with a shaftassembly (200) with an articulated end effector (240). It will beappreciated that the user may wish to use shaft assembly (200) in theposition shown in FIG. 18D or may wish to pivot end effector (240)further by one or more additional articulation increments. In the eventthat the user does not rotate articulation knob (235) further, thelocking of lock tooth (336) between first cam teeth (333) and second camteeth (335) prevents end effector (240) from pivoting to return to astraight position. Once end effector (240) has been articulated to adesired angle (a), it will be understood that the user may actuatefiring beam (282) to drive knife member (280) to cut and drive staples(77) through tissue. For instance, knife member (280) and firing beam(282) may be in communication through, for instance, a bendable beamsuch that firing beam (282) can advance through any degree of pivot ofarticulation joint (234).

FIG. 18E shows a fifth stage of actuation for articulation joint (234)in the event that the user wishes to pivot end effector (240) further.Once again, it will be understood that user continues to rotatearticulation control knob (235). As a result, arms (242, 244) continueto move such that first arm (242) moves distally further and second arm(244) moves proximally further. Movement of arms (242, 244) continues torotate first cam member (330), which causes cam wing (339) to push boss(373) rotationally. First cam member (330) and second cam member (331)move similarly as shown in FIGS. 18B-D, which causes end effector (240)to articulate further as well as lock in a more articulated position. Itwill be understood that the user may continue to rotate articulationcontrol knob (235) to cause end effector (240) to pivot as far as theuser desires. Furthermore, the user may rotate articulation control knob(235) in the opposite direction to cause arms (242, 244) and cam members(330, 331) to move in the opposite direction, thereby causing endeffector (240) to articulate in an opposite direction.

As seen in the exemplary actuation shown in FIGS. 18A-18E, first cammember (330) is operable to unlock articulation joint (234) and pivotend effector (240) at articulation joint (234) about pivot axis (380),by transferring motion from arms (242, 244) to first cam member (330).In addition, second cam member (331) and lock bar (262) cooperate tolock articulation joint (234), to thereby lock the angle (a) of endeffector (240) relative to the longitudinal axis (LA) of shaft assembly(200).

III. Exemplary Alternative Articulation Joints

In some instances, it may be desirable to provide alternative structuresand methods for selectively locking and unlocking articulation joint(234). It may also be desirable to modify the structures and methodsthat are used to drive articulation joint (234) based on the alternativestructures and methods that are used to selectively lock and unlockarticulation joint (234). Various examples of alternative structures andmethods that may be used to provide selective locking and unlocking ofan articulation joint are described in greater detail below, while otherexamples will be apparent to those of ordinary skill in the art in viewof the teachings herein. Similarly, various examples of alternativestructures and methods that may be used to drive an articulation jointare described in greater detail below, while other examples will beapparent to those of ordinary skill in the art in view of the teachingsherein. It should be understood that the following examples may bereadily incorporated into articulation joint (234); or be readilyeincorporated into shaft assembly (200) in place of articulation joint(234). Various suitable ways in which the following examples may beincorporated into instrument (10) will be apparent to those of ordinaryskill in the art.

A. Exemplary Articulation Joint with Complementary Locking Members

FIGS. 20-22B show an exemplary alternative articulation joint (1034)which may be readily incorporated into shaft assembly (200).Articulation joint (1034) utilizes corresponding complementary lockingmembers (1030, 1031) to lock and unlock articulation of end effector(240) at articulation joint (1034). In particular, FIG. 33 shows a firstlocking member (1030) and a second locking member (1031). As can beseen, locking members (1030, 1031) comprise a plurality of complementaryinterlocking features (1022). In the present example, each interlockingfeature (1022) is generally shaped as a triangular protrusion (1023).Collectively, each interlocking feature (1022) is arranged around agenerally conical internal diameter of each locking member (1030, 1031)to form a starburst pattern, with each protrusion (1023) forming anadjacent triangular trough (1024). In addition, each interlockingfeature (1022) on first locking member (1030) is aligned to correspondto another interlocking feature (1022) on second locking member (1031)such that the first locking member (1030) and second locking member(1031) interlock with one another. In other words, for a givenprotrusion (1023) of first locking member (1030), there is acorresponding trough (1024) of second locking member (1031).Accordingly, when second locking member (1031) is inserted in firstlocking member (1030), first locking member (1030) and second lockingmember (1031) become interlocked such that they are rotationally fixedrelative to each other. Second locking member (1031) is unitarilysecured to end effector (240). Thus, when first locking member (1030)and second locking member (1031) are interlocked, the articulationposition of end effector (240) is fixed.

Although locking members (1030, 1031) are shown as having triangularprotrusions (1023), it should be understood that any other suitablegeometry may be used. For instance, in other examples, a square, curved,or wavy geometry may be used. Additionally, although the present exampleis depicted as having a certain number of protrusions (1023), anysuitable number of protrusions may be used. Of course, any otherconfiguration suitable to lock relative rotation between locking members(1030, 1031) may be used as will be apparent to those of ordinary skillin the art in view of the teachings herein.

FIG. 21 shows a plan view of articulation joint (1034) with lockingmembers (1030, 1031) are incorporated therein. As can be seen,articulation joint (1034) comprises a first arm (1042), a second arm(1043), a shaft (1025), and locking members (1030, 1031). Lockingmembers (1030, 1031) are coaxially disposed about shaft (1025), which isoriented perpendicular to the longitudinal axis (LA) of shaft assembly(200). First locking member (1030) is keyed to shaft (1025) such thatfirst locking member (1030) may translate along shaft (1025) but notrotate about shaft (1025). Second locking member (1031) is coupled withshaft such that second locking member (1031) can rotate about shaft(1025) but not translate along shaft (1025). Various ways in which theserelationships may be provided will be apparent to those of ordinaryskill in the art in view of the teachings herein. In the presentexample, second locking member (1031) is shown partially cut away sothat the interaction between first arm (1042) and first locking member(1030) is visible. As will be described in greater detail below, firstarm (1042) is operable to lock and unlock articulation of end effector(240) at articulation joint (1034) by disengaging (lock) or engaging(unlock) first locking member (1030). In contrast, second arm (1044) issecured to second locking member (1031) and is operable to articulatearticulation joint (1034), as will be described in greater detail below.Thus, when articulation joint (1034) is unlocked, second locking member(1031) is operable to rotate about shaft (1025) thereby articulating endeffector (240) relative to the longitudinal axis (LA) of shaft assembly(200).

FIGS. 22A-B show cross-sectional views of exemplary operational statesof articulation joint (1034). In particular, FIG. 22A shows articulationjoint (1034) in a locked state. In the locked state, first lockingmember (1030) is urged into engagement with second locking member (1031)by a conical spring washer (1026) positioned around shaft (1025) andbeneath first locking member (1030). As described above, first lockingmember (1030) is keyed to shaft (1025) such that first locking member(1030) can translate up and down relative to shaft (1025) but not rotateabout shaft (1025). Accordingly, when first locking member (1030) isurged into engagement with second locking member (1031), first lockingmember (1030) prevents rotation of second locking member (1031) relativeto shaft (1025) thereby locking articulation of articulation joint(1034). Shaft (1025) is shown as being fixed in place by a pair ofretaining plates (1021).

FIG. 22B shows articulation joint (1034) in an unlocked state. In theunlocked state, first arm (1042) is actuated distally to engage firstlocking member (1030). First arm (1042) comprises an obliquely angleddistal end (1045) that engages first locking member (1030), urging firstlocking member (1030) downwardly against the resilient bias provided byconical spring washer (1026). With first locking member (1030) urgeddownwardly, first locking member (1030) and second locking member (1031)become disengaged, thereby freeing second locking member (1031) torotate about shaft (1025). With second locking member (1031) freelyrotatable about shaft (1025), second arm (1044) may be actuated distallyor proximally to articulate articulation joint (1034) counter clockwiseor clockwise, respectively. Once a desired articulation angle isachieved, first arm (1042) may be retracted proximally. Conical springwasher (1026) returns first locking member (1030) to the upward positionshown in FIG. 22A, thereby locking end effector (240) at the desiredarticulation angle at articulation joint (1034).

It should be understood that since first arm (1042) and second arm(1044) perform separate functions (e.g., locking/unlocking and rotatingvs. only rotating), first arm (1042) and second arm (1044) may beactuated independently. As described above, this may includearticulation control knob (35) being configured to actuate first arm(1042) and second arm (1044) independently. Alternatively, separate userinput features may be provided to control arms (1042, 1044) separately,as described above.

B. Exemplary Articulation Joint with Helical Cam Member

FIGS. 23-25 show an exemplary alternative articulation joint (1134)which may be readily incorporated into shaft assembly (200).Articulation joint (1134) utilizes a helical cam member (1130) to lockand unlock articulation of end effector (240) at articulation joint(1134). As can be seen in FIG. 23, helical cam member (1130) isconfigured to receive a shaft (1131). As will be described in greaterdetail below, shaft (1131) is configured to translate about itslongitudinal axis (but not rotate about its longitudinal axis) relativeto helical cam member (1130) to lock and unlock articulation of endeffector (240) at articulation joint (1134). Helical cam member (1130)is generally disk shaped, although helical cam member may be a varietyof differing shapes. Helical cam member (1130) comprises a recessed hole(1122) through its center. On the underside of cam member (1130), afrustoconical, inwardly extending starburst locking feature (1129) isoriented around the outer edge of hole (1122). The inner diameter ofhole (1122) has a plurality of helical camming features (1123). As canbest be seen in FIG. 24, each helical camming feature (1123) comprises aramped surface (1124) which permits a key (1125) of shaft (1131) totravel along ramped surface (1124). Inwardly extending locking feature(1129) is similar to second locking member (1031) described above and islikewise configured to engage with a complementary outwardly extendingstarburst locking feature (1128) of a locking member (1162), as will bedescribed in greater detail below.

Shaft (1131) is generally cylindrical in shape and includes an integralkey (1125) protruding radially outwardly from shaft (1131). The diameterof shaft generally corresponds to the inner diameter of hole (1122) ofhelical cam member (1130). Key (1125) is likewise sized to fit withineach helical camming feature (1123) of helical cam member (1130). Thus,when shaft (1131) is inserted into hole (1122) of helical cam member(1130), key (1125) operable to travel along a particular helical cammingfeature (1123) of helical cam member (1130). Key (1125) may travel alonghelical camming feature (1123) of helical cam member (1130) as shaft(1131) is rotated relative to helical cam member (1130). Because helicalcamming feature (1123) is ramped, key (1125) is operable to translateshaft (1131) along the longitudinal axis of shaft (1131) as helical cammember (1130) is rotated about the longitudinal axis of shaft (1131).Similarly, when helical cam member (1130) is rotated in a clockwise Forinstance, when helical cam member (1130) is rotated in a counterclockwise motion, key (1025) will progressively travel up helicalcamming feature (1123) translating key (1125) out of opening (1122).motion, key (1125) will progressively travel down helical cammingfeature (1123) translating key (1125) along with shaft (1131) furtherinside of opening (1122). When key (1125) reaches the bottom of helicalcamming feature (1123) (e.g., when helical cam member (1130) is rotatingwith a counter clockwise motion), key (1125) may then travel along theexterior of helical cam member (1130) until it reaches the next helicalcamming feature (1123) where key (1125) may translate upwardly to thebottom of the next helical camming feature (1123). Likewise, when key(1125) reaches the top of helical camming feature (1123) (e.g., whenshaft (1131) is rotating with a counter clockwise motion), key (1125)may prevent further clockwise rotation of helical cam member (1130).

FIG. 25A shows a cross-sectional view of articulation joint (1134). Ascan be seen, shaft (1131) is positioned between two retaining plates(1121) which hold shaft (1131) in position relative to shaft assembly(200). Retaining plates (1121) permit shaft (1131) to translate alongthe longitudinal axis of shaft (1131); yet prevent shaft (1131) fromrotating about the longitudinal axis of shaft (1131). On the upperportion of the bottom retaining plate (1121), a conical spring washer(1126) (e.g., a Bellville washer) is positioned around shaft (1131). Alocking member (1162) is positioned above spring washer (1126). At theproximal end of locking member (1162), the upper surface of lockingmember (1162) comprises outwardly presented locking feature (1128).Locking feature (1128) of locking member (1162) has a starburstconfiguration that complements the starburst configuration of lockingfeature (1129) of helical cam member (1130). Although not shown in FIG.25A, the distal end of locking member (1162) is connected to endeffector (240). Accordingly, locking member (1162) may articulate endeffector (240) by pivoting about the longitudinal axis of shaft (1131).In some versions, locking member (1162) is configured to translaterelative to end effector (240) along the longitudinal axis of shaft(1131), yet end effector (240) still rotates unitarily with lockingmember (1162) about the longitudinal axis of shaft (1131). Varioussuitable relationships that may be provided between locking member(1162) and end effector (240) will be apparent to those of ordinaryskill in the art in view of the teachings herein.

Spring washer (1126) resiliently biases locking member (1162) upwardlyso that locking feature (1128) engages the complementary locking feature(1129) of helical cam member (1130). Thus, in the configuration shown inFIG. 25A, locking member (1162) is in a locked position such thatlocking member (1162) and end effector (240) cannot rotate relative tohelical cam member (1130). Helical cam member (1130) is verticallysecured in position along the longitudinal axis of shaft (1131) suchthat helical cam member (1130) may rotate about the longitudinal axis ofshaft (1131) yet helical cam member cannot translate along thelongitudinal axis of shaft (1131). Various suitable ways in whichhelical cam member (1130) may be secured will be apparent to those ofordinary skill in the art in view of the teachings herein. In thepresent example, articulation joint (1134) includes bushings (1127) oneach surface which contacts shaft (1131). Bushings (1127) may beconfigured to reduce friction and increase the durability of eachrespective surface. Of course, bushings (1127) are entirely optional andmay be omitted in some examples.

As can be seen by comparing FIGS. 25A and 25B, locking member (1162) maybe unlocked and thereby permitted to rotate about shaft (1131) byrotating helical cam member (1130). In particular, FIG. 25A shows afirst arm (1142) in phantom. The first arm (1142) may be attached tohelical cam member (1130) and may be used to rotate helical cam member(1130) about shaft (1131), between the positions shown in FIGS. 25A and25B. As can be seen in FIG. 25B, when helical cam member (1130) isrotated from the position shown in FIG. 25A to the position shown inFIG. 25B, key (1125) of shaft (1131) is driven downwardly by helicalcamming feature (1123) of helical cam member (1130). Key (1125)correspondingly drives locking member (1162) downwardly, such thatlocking feature (1128) of a locking member (1162) disengages lockingfeature (1129) of helical cam member (1130). With locking member (1162)out of engagement with helical cam member (1130), locking member (1162)may be rotated about to shaft (1131) via a second arm (1144) attachedthereto (shown in phantom in FIG. 25A), to thereby articulate endeffector (240).

Once locking member (1162) is rotated to a desired position,articulation joint (1134) may be relocked by returning articulationjoint (1134) to the position shown in FIG. 25A. In particular, helicalcam member (1130) may be rotationally advanced or retracted via firstarm (1142). For instance, if helical cam member (1130) is rotationallyadvanced, key (1125) may engage the next helical camming feature (1123),thus shifting to the top of the next helical camming feature (1123).Similarly, if helical cam member (1130) is rotationally retracted, key(1125) may slide up the ramped surface of the same helical cammingfeature (1123) used to advance key (1125) outwardly. Although helicalcam member (1130) is shown as being used with conical starburst lockingfeatures (1128, 1129), it should be understood that helical cam member(1130) may be used with any suitable locking system utilizing atranslating shaft as will be apparent to those of ordinary skill in theart in view of the teachings herein.

C. Exemplary Articulation Joint with Pivoting Locking Member

FIG. 26 depicts an exemplary alternative articulation joint (1234) foruse with shaft assembly (200) that utilizes a pivoting lock member(1230) to lock and unlock a single lock member (1231). In particular,articulation joint (1234) comprises lock member (1231), pivoting lockmember (1230), a first arm (1242), and a second arm (1244). Lock member(1231) comprises a plurality of holes (1225) which may be used to lockarticulation joint (1234) in a plurality of discrete articulationpositions, with each articulation position having a specific angle (a)relative to the longitudinal axis (LA) of shaft assembly (200). Similarto articulation joint (234), articulation joint (1234) is rotatableabout a central shaft (1279) to achieve articulation. Central shaft(1279) extends along an axis that is perpendicular to the longitudinalaxis (LA) of shaft assembly (200). Although not shown in FIG. 26, itshould be understood that the distal end of lock member (1231) may beunitarily attached to end effector (240). Thus, rotation of lock member(1231) about central shaft (1279) causes end effector (240) toarticulate about the longitudinal axis of central shaft (1279) atarticulation joint (1234).

Lock member (1230) is generally L-shaped with a pivot portion (1226) anda locking portion (1227). Pivot portion (1226) is configured to pivotabout a pivot shaft (1228) to pivot locking portion (1227) into and outof engagement with lock member (1231) thereby locking and unlocking lockmember (1231), respectively. Locking portion (1227) is configured to fitwithin each hole (1225) of lock member (1231). Pivot shaft (1228) isoriented along an axis that is substantially perpendicular thelongitudinal axis of central shaft (1279). The axis of pivot shaft(1228) is also perpendicular to the longitudinal axis (LA) of shaftassembly (200).

In an exemplary mode of operation, articulation joint (1234) is operableto articulate using independently actuated first arm (1242) and secondarm (1244). For instance, first arm (1242) is shown as being pivotallyattached to pivot portion (1226) of lock member (1230) via a pin (1229).Accordingly, first arm (1242) may be actuated distally to pivot lockingportion (1227) of lock member (1230) into a hole (1225) of lock member(1230), thereby locking articulation joint (1234). Likewise, first arm(1242) may also be actuated proximally to pivot locking portion (1227)of lock member (1230) out of a hole (1225) of lock member (1230) therebyunlocking articulation joint (1234). When articulation joint (1234) isunlocked, second arm (1244), which is attached to lock member (1231),may be actuated to rotate lock member (1231) about central shaft (1279)thereby articulating articulation joint (1234). Second arm (1244) may beactuated proximally or distally depending upon whether a clock wise orcounter clockwise articulation is desired. Once a desired articulationposition is reached, end effector (240) may be relocked at the desiredarticulation position at articulation joint (1234) by pivoting lockmember (1230) into engagement with a new hole (1225) via distaladvancement of first arm (1242).

D. Exemplary Articulation Joint with Translating Locking Member

FIGS. 27-28 depict an exemplary alternative articulation joint (1334)for use with shaft assembly (200) that utilizes a translating lockmember (1330) to lock and unlock a single lock member (1331). Inparticular, articulation joint (1334) comprises lock member (1331),translating lock member (1330), a first arm (1342), and a second arm(1344). Lock member (1331) comprises a plurality of holes (1325) whichmay be used to lock articulation joint (1334) in a plurality of discretearticulation positions, with each articulation position having aspecific angle (a) relative to the longitudinal axis (LA) of shaftassembly (200). Similar to articulation joint (234), articulation joint(1334) is rotatable about a central shaft (1379) to achievearticulation. Central shaft (1379) extends along an axis that isperpendicular to the longitudinal axis (LA) of shaft assembly (200).Although not shown in FIG. 27, it should be understood that the distalend of lock member (1331) may be unitarily attached to end effector(240). Thus, rotation of lock member (1331) about central shaft (1379)causes end effector (240) to articulate about the longitudinal axis ofcentral shaft (1379) at articulation joint (1334).

FIG. 28 shows a cross-sectional view of lock member (1330). As can beseen, lock member (1330) comprises a translatable locking feature(1326), a spring (1327), and a casing (1328). Locking feature (1326) isgenerally cylindrical in shape such that locking feature (1326) maytranslate along an axis that is both perpendicular to the longitudinalaxis (LA) of shaft assembly (200) and parallel to the longitudinal axisof central shaft (1379). In particular, locking feature (1326) isoperable to translate into and out of a hole (1325) of lock member(1331). Locking feature (1326) is resiliently biased upwardly by spring(1327). Although spring (1327) is shown as resiliently biasing lockingfeature (1326), it should be understood that any suitable means may beused to resiliently bias locking feature (1326) upwardly. Casing (1328)is configured to surround locking feature (1326) such that lockingfeature (1326) may slidably engage with casing (1328). Casing (1328) isshown as having a transverse bore (1329) which, as will be described ingreater detail below, permits first arm (1342) to translate into and outof casing (1328) so that an obliquely angled distal end (1343) of firstarm (1342) may actuate locking feature (1326).

In an exemplary mode of operation, articulation joint (1334) is operableto articulate using independently actuated first arm (1342) and secondarm (1344). For instance, first arm (1242) is shown as beingtranslatable into and out of casing (1328) of lock member (1330). Inparticular, as can be seen in FIG. 41, oblique distal end (1343) offirst arm (1342) is operable to drive locking feature (1326) of lockmember (1330) downwardly through a camming action when first arm (1342)is actuated distally. Thus, distal actuation of first arm (1342) isoperable to translate locking feature (1326) downwardly into a hole(1325) of lock member (1321) to lock articulation joint (1334).Likewise, first arm (1342) may also be actuated proximally to disengagelocking feature (1326) of lock member (1330) to permit spring toresiliently drive locking feature (1326) upwardly and out of engagementwith a hole (1325) of lock member (1330). Thus, proximal actuation offirst arm (1342) will unlock articulation joint (1334). Whenarticulation joint (1334) is unlocked, second arm (1344), which isattached to lock member (1331), may be actuated to rotate lock member(1331) about central shaft (1379) thereby articulating articulationjoint (1334). Second arm (1344) may be actuated proximally or distallydepending upon whether a clock wise or counter clockwise articulation isdesired. Once a desired articulation position is reached, end effector(240) may be relocked at the desired articulation position atarticulation joint (1334) by actuating locking feature (1326) intoengagement with a new hole (1325) via distal advancement of first arm(1342).

IV. Miscellaneous

It should be understood that in the various examples described above, anarticulation joint is configured to permit an end effector to articulatealong a first plane and thereby deflect away from the longitudinal axisof a shaft assembly. A locking assembly is operable to selectively lockthe articulation joint. The locking assembly includes a locking memberthat is movable along a second plane to selectively engage the firstlocking member and thereby lock the articulation joint. The second planeis offset from the first plane. The second plane is also non-parallelwith the first plane. In some instances, the second locking member ismovable along a second axis that is perpendicular to the longitudinalaxis of the shaft assembly. An unlocking member may selectively drivethe locking member. The unlocking member may move along a third plane,which may be offset from and/or in a non-parallel relationship with thefirst and/or second plane(s). The unlocking member may move along athird axis, which may be perpendicular to the longitudinal axis of theshaft assembly and/or the second axis.

It should be understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Theabove-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims. It should also be understoodthat the various teachings herein may be readily combined with theteachings of the various references that are cited herein. In addition,the various teachings herein may be readily combined with the teachingsof U.S. Pub. No. 2015/0374362, entitled “Method of UnlockingArticulation Joint in Surgical Stapler,” published Dec. 31, 2015, thedisclosure of which is incorporated by reference herein; and/or theteachings of U.S. Pub. No. 2015/0374364, published Dec. 31, 2015,entitled “Translatable Articulation Joint Unlocking Feature for SurgicalStapler,” now U.S. Pat. No. 9,693,774, issued Jul. 4, 2017, thedisclosure of which is incorporated by reference herein.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.Similarly, those of ordinary skill in the art will recognize thatvarious teachings herein may be readily combined with various teachingsof any of the following: U.S. Pat. No. 5,792,135, entitled “ArticulatedSurgical Instrument For Performing Minimally Invasive Surgery WithEnhanced Dexterity and Sensitivity,” issued Aug. 11, 1998, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.5,817,084, entitled “Remote Center Positioning Device with FlexibleDrive,” issued Oct. 6, 1998, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 5,878,193, entitled “Automated EndoscopeSystem for Optimal Positioning, ” issued Mar. 2, 1999, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 6,231,565,entitled “Robotic Arm DLUS for Performing Surgical Tasks,” issued May15, 2001, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 6,783,524, entitled “Robotic Surgical Tool with UltrasoundCauterizing and Cutting Instrument,” issued Aug. 31, 2004, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.6,364,888, entitled “Alignment of Master and Slave in a MinimallyInvasive Surgical Apparatus,” issued Apr. 2, 2002, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 7,524,320,entitled “Mechanical Actuator Interface System for Robotic SurgicalTools,” issued Apr. 28, 2009, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 7,691,098, entitled “Platform Link WristMechanism,” issued Apr. 6, 2010, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 7,806,891, entitled “Repositioningand Reorientation of Master/Slave Relationship in Minimally InvasiveTelesurgery,” issued Oct. 5, 2010, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2013/0012957, entitled“Automated End Effector Component Reloading System for Use with aRobotic System, published Jan. 10, 2013, now U.S. Pat. No. 8,844,789,issued Sep. 30, 2014, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0199630, entitled“Robotically-Controlled Surgical Instrument with Force-FeedbackCapabilities,” published Aug. 9, 2012, now U.S. Pat. No. 8,820,605,issued Sep. 2, 2014, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0132450, entitled “Shiftable DriveInterface for Robotically-Controlled Surgical Tool,” published May 31,2012, now U.S. Pat. No. 8,616,431, issued Dec. 31, 2013, the disclosureof which is incorporated by reference herein; U.S. Pub. No.2012/0199633, entitled “Surgical Stapling Instruments with Cam-DrivenStaple Deployment Arrangements,” published Aug. 9, 2012, now U.S. Pat.No. 8,573,461, issued Nov. 5, 2013, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2012/0199631, entitled“Robotically-Controlled Motorized Surgical End Effector System withRotary Actuated Closure Systems Having Variable Actuation Speeds,”published Aug. 9, 2012, now U.S. Pat. No. 8,602,288, issued Dec. 10,2013, the disclosure of which is incorporated by reference herein; U.S.Pub. No. 2012/0199632, entitled “Robotically-Controlled SurgicalInstrument with Selectively Articulatable End Effector,” published Aug.9, 2012, now U.S. Pat. No. 9,301,759, issued Apr. 5, 2016, thedisclosure of which is incorporated by reference herein; U.S. Pub. No.2012/0203247, entitled “Robotically-Controlled Surgical End EffectorSystem,” published Aug. 9, 2012, now U.S. Pat. No. 8,783,541, issuedJul. 22, 2014, the disclosure of which is incorporated by referenceherein; U.S. Pub. No. 2012/0211546, entitled “Drive Interface forOperably Coupling a Manipulatable Surgical Tool to a Robot,” publishedAug. 23, 2012; now U.S. Pat. No. 8,479,969, issued Jul. 9, 2013; U.S.Pub. No. 2012/0138660, entitled “Robotically-Controlled Cable-BasedSurgical End Effectors,” published Jun. 7, 2012, now U.S. Pat. No.8,800,838, issued Aug. 12, 2014, the disclosure of which is incorporatedby reference herein; and/or U.S. Pub. No. 2012/0205421, entitled“Robotically-Controlled Surgical End Effector System with RotaryActuated Closure Systems,” published Aug. 16, 2012, now U.S. Pat. No.8,573,465, issued Nov. 5, 2013, the disclosure of which is incorporatedby reference herein.

Versions of the devices described above may be designed to be disposedof after a single use, or they can be designed to be used multipletimes. Versions may, in either or both cases, be reconditioned for reuseafter at least one use. Reconditioning may include any combination ofthe steps of disassembly of the device, followed by cleaning orreplacement of particular pieces, and subsequent reassembly. Inparticular, some versions of the device may be disassembled, and anynumber of the particular pieces or parts of the device may beselectively replaced or removed in any combination. Upon cleaning and/orreplacement of particular parts, some versions of the device may bereassembled for subsequent use either at a reconditioning facility, orby a user immediately prior to a procedure. Those skilled in the artwill appreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

We claim:
 1. An apparatus comprising: (a) a body; (b) a shaft assemblyextending distally from the body, wherein the shaft assembly defines alongitudinal axis, wherein the shaft assembly has a distal end; (c) anend effector, wherein the end effector is operable to manipulate tissue;(d) an articulation joint coupling the end effector with the distal endof the shaft assembly, wherein the articulation joint is configured topermit the end effector to articulate along a first plane and therebydeflect away from the longitudinal axis of the shaft assembly; and (e) alocking assembly operable to selectively lock the angular position ofthe end effector relative to the longitudinal axis of the shaftassembly, wherein the locking assembly comprises: (i) a first lockingmember unitarily secured to the end effector, such that the firstlocking member is configured to move with the end effector relative tothe longitudinal axis of the shaft assembly, and (ii) a second lockingmember operable to selectively engage the first locking member tothereby selectively lock the angular position of the end effectorrelative to the longitudinal axis of the shaft assembly, wherein thesecond locking member is movable along a second plane to selectivelyengage the first locking member, wherein the second plane is offset fromthe first plane, and wherein the second plane is non-parallel with thefirst plane; wherein the locking assembly further comprises an unlockingfeature, wherein the unlocking feature is operable to selectivelydisengage the second locking member from the first locking member; andwherein the second locking member is movable along a first axis, whereinthe unlocking feature is operable to translate along a second axis tothereby selectively disengage the second locking member from the firstlocking member, wherein the second axis is perpendicular to the firstaxis.
 2. The apparatus of claim 1, wherein the second axis is parallelwith the longitudinal axis of the shaft assembly.
 3. The apparatus ofclaim 1, wherein the unlocking feature includes a distal end having acamming feature, wherein the camming feature is operable to drive thesecond locking member along the second axis in response to translationof the unlocking feature along the second axis.
 4. The apparatus ofclaim 1, wherein the unlocking feature is operable to rotate about afirst axis to thereby selectively disengage the second locking memberfrom the first locking member.
 5. The apparatus of claim 4, wherein thesecond locking member is movable along a second axis, wherein the firstaxis and the second axis are coextensive with each other.
 6. Theapparatus of claim 5, wherein the second locking member and theunlocking feature are both coaxially disposed about the first and secondaxes.
 7. The apparatus of claim 4, wherein the unlocking featurecomprises a helical cam feature operable to bear against the secondlocking member.
 8. The apparatus of claim 7, wherein the second lockingmember comprises an outwardly extending key configured to engage thehelical cam of the unlocking feature.
 9. The apparatus of claim 1,wherein the second locking feature is resiliently biased to engage thefirst locking feature.
 10. The apparatus of claim 1, wherein thearticulation joint is configured to permit the end effector to pivotabout a first axis to thereby permit the end effector to deflect awayfrom the longitudinal axis of the shaft assembly.
 11. The apparatus ofclaim 10, wherein the second locking member is movable along a secondaxis, wherein the first axis and the second axis are coextensive witheach other.
 12. The apparatus of claim 1, wherein the first and secondlocking members comprise complementary starburst features.
 13. Theapparatus of claim 1, wherein the shaft assembly further comprises: (i)a first translatable member, wherein the first translatable member isoperable to selectively drive the second locking member, and (ii) asecond translatable member, wherein the second translatable member isoperable to selectively drive the end effector to deflect the endeffector from the longitudinal axis of the shaft assembly at thearticulation joint.
 14. The apparatus of claim 1, wherein the firstlocking member defines a plurality of openings, each opening beingassociated with a different angular position of the end effectorrelative to the longitudinal axis of the shaft assembly, wherein eachopening is configured to selectively receive a portion of the secondlocking member to thereby selectively lock the angular position of theend effector relative to the longitudinal axis of the shaft assembly.15. The apparatus of claim 1, wherein the end effector comprises astapling assembly operable to drive staples into tissue.
 16. Anapparatus comprising: (a) a body; (b) a shaft assembly extendingdistally from the body, wherein the shaft assembly defines alongitudinal axis, wherein the shaft assembly has a distal end; (c) anend effector, wherein the end effector is operable to manipulate tissue;(d) an articulation joint coupling the end effector with the distal endof the shaft assembly, wherein the articulation joint is configured topermit the end effector to pivot about a pivot axis to thereby pivotaway from the longitudinal axis of the shaft assembly; and (e) a lockingassembly operable to selectively lock the angular position of the endeffector relative to the longitudinal axis of the shaft assembly,wherein the locking assembly comprises: (i)a first locking memberunitarily secured to the end effector proximal to the pivot axis, suchthat the first locking member is configured to pivot with the endeffector about the pivot axis, (ii) a second locking member operable toselectively engage the first locking member to thereby selectively lockthe angular position of the end effector relative to the longitudinalaxis of the shaft assembly, wherein the second locking member is movablealong the pivot axis to selectively engage the first locking member; and(iii) an unlocking feature operable to selectively disengage the secondlocking member from the first locking member, wherein the unlockingfeature is operable to translate along an axis that is perpendicular tothe pivot axis to thereby selectively disengage the second lockingmember from the first locking member.
 17. An apparatus comprising: (a) abody; (b) a shaft assembly extending distally from the body, wherein theshaft assembly defines a longitudinal axis, wherein the shaft assemblyhas a distal end; (c) an end effector, wherein the end effector isoperable to manipulate tissue; (d) an articulation joint coupling theend effector with the distal end of the shaft assembly, wherein thearticulation joint is configured to permit the end effector toarticulate along a first plane and thereby deflect away from thelongitudinal axis of the shaft assembly; and (e) a locking assemblyoperable to selectively lock the angular position of the end effectorrelative to the longitudinal axis of the shaft assembly, wherein thelocking assembly comprises: (i) a first locking member unitarily securedto the end effector, such that the first locking member is configured tomove with the end effector relative to the longitudinal axis of theshaft assembly, and (ii) a second locking member operable to selectivelyengage the first locking member to thereby selectively lock the angularposition of the end effector relative to the longitudinal axis of theshaft assembly, wherein the second locking member is movable along asecond plane to selectively engage the first locking member, wherein thesecond plane is offset from the first plane, and wherein the secondplane is non-parallel with the first plane; wherein the locking assemblyfurther comprises an unlocking feature operable to selectively disengagethe second locking member from the first locking member, wherein thesecond locking member is movable along a first axis; and wherein theunlocking feature is operable to translate along a second axis tothereby selectively disengage the second locking member from the firstlocking member, wherein the second axis is perpendicular to the firstaxis, wherein the unlocking feature includes a distal end having acamming feature, wherein the camming feature is operable to drive thesecond locking member along the second axis in response to translationof the unlocking feature along the second axis.
 18. The apparatus ofclaim 17, wherein the second axis is parallel with the longitudinal axisof the shaft assembly.